Slipper clutch conversion project

[GregT]

You should really confirm the spline interchange with Agemax. If they are tha same all it means is that the late GSXR600 clutch hub is a starting point for a slipper conversion. I can confirm that the GSXR1000 spline is quite different to the early GS's.

What is stopping a lot of us from going ahead are the sanctioning body rules....Given that the ZX7 appears to have been the first sportbike marketed with a slipper clutch - in 1988/89 - no body I know of will yet accept slippers in forgotten era/pre 82 or whatever name it goes under where you are....

[ashdricky]

You should really confirm the spline interchange with Agemax. If they are tha same all it means is that the late GSXR600 clutch hub is a starting point for a slipper conversion. I can confirm that the GSXR1000 spline is quite different to the early GS's.

What is stopping a lot of us from going ahead are the sanctioning body rules....Given that the ZX7 appears to have been the first sportbike marketed with a slipper clutch - in 1988/89 - no body I know of will yet accept slippers in forgotten era/pre 82 or whatever name it goes under where you are....

I didn't take road racing into consideration when I started this build, the next bike I build might be track only, this bike is just supposed to be my road bike, maybe use it for Alpine club rallys or something like that. Mainly these odd projects are for educational purposes, and to have something that Jay Leno dose not have.

[Agemax]

You should really confirm the spline interchange with Agemax. If they are tha same all it means is that the late GSXR600 clutch hub is a starting point for a slipper conversion. I can confirm that the GSXR1000 spline is quite different to the early GS's.

What is stopping a lot of us from going ahead are the sanctioning body rules....Given that the ZX7 appears to have been the first sportbike marketed with a slipper clutch - in 1988/89 - no body I know of will yet accept slippers in forgotten era/pre 82 or whatever name it goes under where you are....

i dont know how i can help, but i will if i can!

[ashdricky]

Agemax, I believe that at some point in the past you posted that the retaining washer for the gearbox input shaft is the same part number for all models, indicating that the splines are the same for the different motors.

[Agemax]

Agemax, I believe that at some point in the past you posted that the retaining washer for the gearbox input shaft is the same part number for all models, indicating that the splines are the same for the different motors.

i remember now, that was the clutch hub washer, yes it fits multiple models but it is not splined, just a round hole.....

[GregT]

i remember now, that was the clutch hub washer, yes it fits multiple models but it is not splined, just a round hole.....

Okay, that's the heavy, slightly conical washer. i thought you were referring to the lock washer which is splined.
If someone has a part number for that one it should give a pretty good indication of how many models use that spline.

[Agemax]

Okay, that's the heavy, slightly conical washer.

it is actually flat, with grooves in it. but anyway it doesn't matter now...

[salty_monk]

If I recall correctly I used an 1150 clutch hub nut on my 78 1000E & that was the same as my 83 750E...

[ashdricky]

Dose someone have an old clutch from a 1000 that they would be willing to donate or let go for a reasonable price? And are the clutch specs the same for the 1000-1150?

[Agemax]

i replaced the clutch plates on a Aprillia RSV Mille yesterday. the slipper clutch design on that bike is so simple and would be an easy mod to do on any GS with a bit of machining.
as long as it has the "pushrod through the shaft" set up, rather than the actuator in the clutch cover.

i am toying with making one for my GS1000, as i have the hydraulic clutch conversion so there is no actuator in the cover itself.

[ashdricky]

Is there any chance that the drive splines are similar to the GS?

[Agemax]

Is there any chance that the drive splines are similar to the GS?

you use the complete stock clutch, you will need to machine the stock GS clutch cover to fit the Aprilia end cover.
it works by vacuum. a big diaphragm is bolted to the centre of the clutch pressure plate, on the release pushrod. the end cover is sealed with a tube attached which connects to the vacuum ports on the inlets.
when you throttle off the vacuum in the inlet tracts pull on the diaphragm and disengage the clutch just enough to allow it to slip slightly.

sounds too simple but it really works

[ashdricky]

I am back stateside and have made more progress on this clutch, here are some photos I took today.







I must now machine the backside of the slipper cam as well as the inside of the hub to get the retaining nut to thread down all the way, then I can machine the back of the basket to have the correct spacing from the primary drive gear.

[ashdricky]

you use the complete stock clutch, you will need to machine the stock GS clutch cover to fit the Aprilia end cover.
it works by vacuum. a big diaphragm is bolted to the centre of the clutch pressure plate, on the release pushrod. the end cover is sealed with a tube attached which connects to the vacuum ports on the inlets.
when you throttle off the vacuum in the inlet tracts pull on the diaphragm and disengage the clutch just enough to allow it to slip slightly.

sounds too simple but it really works

I was thinking about what you said in this quote regarding a vacuum operated clutch, did you actually test fit this on your splines? as for my project I had to machine the BTL Cam shorter to get everything to fit correctly. also I was wondering about the ease of tuning GSX-R lift pins to adjust slip percentages vs tuning the amount of slip from the vacuum operated mechanism.

[Agemax]

i dont need to test fit anything, as it will work with the stock GS clutch assembly